Changeover process improvement based on modified SMED method and other process improvement tools application: an improvement project of 5-axis CNC machine operation in advanced composite manufacturing industry

Abstract

This paper shares a real industry experience for an improvement project of the changeover process through a conventional Single-Minute Exchange Die (SMED) method and other process improvement application tools. This project focuses on the changeover activities for one of the advanced composite manufacturing processes, called trimming process that involves 5-axis CNC machine operation. The cause and effect and five whys analysis techniques and some steps of conventional SMED are applied in this improvement project. Four standard strategies and priorities sequence are introduced for an extension step of conventional SMED. The conceptual decision model is then proposed to present the systematic improvement process carried out in this project. Four specific solutions from the selected strategies are then recommended to be implemented. The current implementation results show that the total changeover time is reduced to 44% and internal type activities time is reduced to 48%. The paper discusses some key success factors and future recommendations of the current project.